Method and system for operating a racking system preferably in a dispatch unit

ABSTRACT

A method for operating a rack system preferably in a dispatch unit ( 1 ), with a rack ( 2 ) and an associated rack serving device for the storage and retrieval of containers ( 3 ), trays or the like to or from the rack. A rack region of the rack ( 2 ) has a plurality of rack planes ( 13 ) arranged one above the other and is served by a dedicated, mechanically coupled, height and length-adjustable rack serving device ( 4 ). In each track region embodied as an independent, closed rack unit (A, B, C), containers ( 3 ), trays or the like undergo interim storage in a buffer zone (P 1 , P 2 , P 3 ) on the same level, are transferred for storage or retrieval and transported by an elevator ( 5; 6   a   , 6   b ) and/or a preferably horizontal transport connection (F 1 , F 2 ) arranged in the region of the rack unit (A, B, C) at the same level, from or to a transport system or workplace outside the rack system.

FIELD OF THE INVENTION

[0001] The present invention pertains to a method and a system foroperating a rack system preferably in a dispatch unit, with a rack andan associated rack serving device for the storage and retrieval ofcontainers, trays or the like into or out of the rack.

[0002] Whenever the term “container” is used below it shall not bedefined in a limiting manner; the present invention rather alsocomprises systems in which other transport units, e.g., trays or palletsare used to store and transport the product to be dispatched.

BACKGROUND OF THE INVENTION

[0003] According to a known prior art, containers are removed from acontainer storage area and sent via a height-adjustable rack servingdevice, which can be displaced along the container storage area, to acentral distribution system, which joins the container storage area. Inparticular, the rack serving device serves two opposite storage racksover the entire height of the rack (cf. DE 197 12 839 A1). The limiteddispatch output and inflexibility of the rack serving system is adisadvantage.

SUMMARY OF THE INVENTION

[0004] The object of the present invention is essentially to make theprior-art method and system more efficient and to correspondingly makeavailable with simple means an efficient method and an efficient servingsystem for operating a rack system preferably in a dispatch unit.

[0005] The essence of the method according to the present invention isthat a rack region of the rack system, which rack region comprises aplurality of rack planes arranged one above the other, is served by adedicated, mechanically coupled, height- and length-adjustable rackserving device, and that containers, trays or the like, which are takenover by the rack serving device for storage or released for retrievaland are transported by means of at least one elevator and/or a transportconnection from or to a transport system or workplace located outsidethe rack system, are stored on an interim basis in a buffer zone locatedon the same level as an interface to the outside in each rack regionembodied as an independent and closed rack unit.

[0006] The containers are preferably transported via the horizontaltransport connection arranged on the same level in the region of therack unit without crossing to or from an individual workplace,especially to or from an individual dispatch place of a dispatch unit,preferably on a closed path, in a so-called “loop.”

[0007] Consequently, the rack in a rack serving system according to thepresent invention is divided into at least two rack regions arranged oneabove the other, which comprise a plurality of adjacent rack planesarranged one above the other each, wherein each rack region has as anindependent and closed rack unit a dedicated, mechanically coupled,height- and length-adjustable rack serving device. Each rack servingdevice preferably covers a working range of about 4 m of rack height.Each rack region comprises, in particular, a transfer station, which isa rigid part of the rack and is located on the same level, with a bufferzone as an interface to the outside and, furthermore, at least oneelevator, which joins the buffer zones and is preferably a rigid part ofthe rack, and/or a transport connection, which is connected to eachbuffer zone and is preferably a rigid part of the rack in the rackregion, for feeding or removing containers, trays or the like to or froma transport system or workplace located outside the rack system,preferably without crossing, to and from an individual dispatch place ofa dispatch unit (“product-to-man system”). A plurality of containers,usually containers or boxes, can be picked up and deposited from thevehicle or rack serving device in the buffer zone. The buffer zonestores the products until they can be taken over by the elevator system.The individual, independent and closed planes or rack units and thematerials handling technology located outside the rack system are linkedwith one another by an elevator or with a transport connection. As aresult, a highly flexible interface can be created with the materialshandling technology located outside the rack system and, in particular,a high dispatch capacity can be set up.

[0008] Advantages of the system according to the present invention overthe prior-art system:

[0009] As many planes or rack units as desired can be arranged one aboveanother. Rack heights of 20 m or higher can be attained in a simplemanner. The height of the overall system is limited only by thestability of the rack system and the elevator mast.

[0010] The throughput of the system is higher than in prior-art systemswith only one vehicle or rack serving device for the overall height ofthe rack system. The throughput is determined, besides by the number ofrack serving devices, essentially by the elevator system or thetransport system used for the connection, which links the individualrack serving devices with the materials handling technology locatedoutside the rack system.

[0011] Each plane or rack unit of the rack system is accessible by meansof a ladder. Each rack unit is enclosed in itself. Service and repairoperations can thus be performed on each rack unit separately, withouthaving to put the entire system out of operation. This is an essentialadvantage compared with the prior-art rack serving device. The safety ofthe overall system against failure is thus increased in the longer term.

[0012] The individual vehicles or height-adjustable rack servingdevices, which are longitudinally displaceable at a rack front, arebuilt up such that the mast is arranged centrally at the elevatingchassis. As a result, the actions of forces due to the acceleration andbraking of the vehicle or elevating platform can be minimized, and alightweight design can be optimally implemented.

[0013] By using an elevator system as a link between the individualplanes or rack units and the materials handling technology locatedoutside the rack system, it is possible to serve a larger number oftransfer points and buffer zones of the rack serving vehicles in asimple and effective manner. If a separate elevator is used for thestorage and retrieval of products, high throughputs are possible even inthe case of a small storage area.

[0014] Another advantage is that the vehicles or rack serving devicesare compatible, and a rack serving device can be replaced with a new ordifferent, existing rack serving device in a simple manner.

[0015] It is possible to serve two planes or two rack units of the racksystem with a feeding and removing materials handling technology. Thedifference in height is achieved by an elevating or lowering movement.

[0016] Each plane or each rack unit has an independent, enclosedfunctional area. As a result, separate interfaces of the materialshandling technology can be served as a dedicated overall system. Thisproperty can also be utilized in separate planes as a “product-to-mansystem.” This means that a plurality of independent rack serving systemsfunction in a single mechanical rack system. Optimal use over aplurality of planes of a building is possible as a result.

[0017] Each plane or each rack unit can be operated as a “stand-alonesolution” in respect to the electronic control means. However, it isalso possible to integrate a plurality of systems in one control.

[0018] The entire rack system can be optimally used for different typesof containers. This means that, e.g., boxes can be dynamically storedand managed in one plane region, but normal containers are stored andmanaged in another plane system. Furthermore, the planes or rack unitsmay also differ in the number of storage depths. This means that oneplane or rack unit is used for two-deep storage, and the other plane orrack unit is used for single-depth or four-deep storage. The greatadvantage is the optimal utilization of the rack system and thesimplicity of the load-carrying means used. The load-carrying means canbe optimally adapted to the requirements. It is also possible, e.g., toarrange special storage means such as flow racks in each plane or rackunit and to serve them with load-carrying means specially designed forthem.

[0019] The rack serving device system is integrated within the rack. Therack accommodates the guiding system for the vehicle system and is thusconsidered to be an integrated system.

[0020] Due to the low overall height of the vehicle system, the overallsystem is very service-friendly, because the individual planes or rackunits can all be reached in a simple manner.

[0021] If a plurality of plane systems serve one plane system or if aplurality of plane systems are integrated in a single plane system, thethroughput is guaranteed by corresponding buffer systems and connectionsystems.

[0022] The various features of novelty which characterize the inventionare pointed out with particularity in the claims annexed to and forminga part of this disclosure. For a better understanding of the invention,its operating advantages and specific objects attained by its uses,reference is made to the accompanying drawings and descriptive matter inwhich preferred embodiments of the invention are illustrated.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023]FIG. 1 is a schematic perspective view of a rack serving systemaccording to the present invention of a dispatch unit, with a compositerack comprising three double racks and three rack serving devices atdifferent heights of the rack;

[0024]FIG. 2 is an enlarged detail of the rack serving system accordingto FIG. 1;

[0025]FIG. 3 is a schematic side view of the rack serving systemaccording to FIG. 1;

[0026]FIG. 4 is a schematic top view of the rack serving systemaccording to FIG. 1;

[0027]FIG. 5 is a schematic side view of the rack serving deviceaccording to FIGS. 1 through 4;

[0028]FIG. 6 is a schematic top view of the rack serving deviceaccording to FIGS. 1 through 4;

[0029]FIG. 7 is a schematic perspective view of another embodimentvariant of a rack serving system according to the present invention of adispatch unit corresponding to FIGS. 1 through 4;

[0030]FIG. 8 is an enlarged detail of the rack serving system accordingto FIG. 7;

[0031]FIG. 9 is a schematic side view of the rack serving systemaccording to FIG. 7; and

[0032]FIG. 10 is a schematic top view of the rack serving systemaccording to FIG. 7.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] Referring to the drawings in particular, according to thedrawings, the container storage area of a dispatch unit 1 comprises acomposite rack 2 comprising three double racks in a parallel arrangementwith longitudinally displaceable rack serving devices 4 according toFIGS. 5 and 6, which are arranged in the rack aisles 14.

[0034] As can be best recognized from FIGS. 3, 4 as well as 9 and 10, adedicated rack serving device 4 is associated with each rack aisle 14.The overall height of the rack is divided into three rack regions, whichare arranged one above the other and comprise eight rack planes 13arranged one above the other each, wherein each rack region has adedicated, mechanically coupled, height- and length-adjustable rackserving device 4 as an independent and closed rack unit A, B and C.

[0035] The rack serving device 4 has an elevating chassis 10 and anelevating platform 11 of a small overall height essentially at the sameheight, the elevating chassis 10 and the elevating platform 11 beingarranged on opposite sides of a longitudinally displaceable, drivenelevator mast 12. The elevator mast 12 extends over the height of eachrack unit A, C and C and is guided at least at its longer longitudinalend in a longitudinal guide rail, which is an integral part of the rack2.

[0036] Each rack region or each rack unit A, B, C has a transfer stationwhich is a rigid part of the rack and is located on the same level witha buffer zone P1, P2 and P3, respectively, for containers 3, in whichsaid buffer zone containers are taken over by the rack serving device 4for storage or are released for retrieval, and, furthermore, elevators 6a, 6 b, which are rigid parts of the rack and are connected to thebuffer stations in the first embodiment variant according to FIGS. 1through 4, or elevators 5 which are rigid parts of the rack in thesecond embodiment variant according to FIGS. 7 through 10, and twohorizontal transport connections F1, F2, which are connected to thebuffer stations P1, P2, are rigid parts of the rack and are located onthe same level in the rack region, for feeding or removing containers 3from or into a transport system or workplace (not shown), which islocated outside the rack system.

[0037] The transport connection F1 and F2, which is on the same level inthe region of the rack unit A, B, C, is led without crossing as a closedtransport loop directly to and from an individual workplace, especiallydirectly to and from an individual dispatch place of a dispatch unit,and containers dispatched from the rack 2 are transported on the saidtransport loop to the workplace and conversely, empty containers orpartially emptied containers 3 are transported from the workplace to therack 2.

[0038] A dedicated electronic control means for the storage andretrieval of containers 3 is provided for each rack unit A, B and C.

[0039] As an alternative, a common electronic control means may also beprovided for at least a plurality of preferably adjacent rack units.

[0040] In both exemplary embodiments according to FIGS. 1 through 4 aswell as according to FIGS. 7 through 10, the buffer zone P1, P2 and P3has stationary parking spaces 9 at the rack 2 at the level of each rackunit A, B, C for the interim storage of containers 3.

[0041] Furthermore, the buffer zone P1, P2 and P3 comprises, in bothembodiment varients, open linear horizontal conveyor tracks 8, likewiseat the level of each rack unit A, B, C, on which containers 3 canlikewise be transported and stored on an interim basis.

[0042] Finally, the buffer zone P1, P2 and P3 according to the secondembodiment variant according to FIGS. 7 through 10 comprise,furthermore, a preferably closed horizontal conveyor track 7 or aconveying loop arranged on the same level with a connection to anelevator 5, on which said track or loop containers can be transportedand stored on an interim basis and transferred to the elevator 8 ortaken over from the elevator 8. The containers 3 are fed and removedhere by means of the common elevator 5, contrary to the first embodimentvariant according to FIGS. 1 through 4, in which the containers 3 arefed and removed by means of elevators 6 a, 6 b.

[0043] Each rack unit A, B or C is accessible by means of a ladder.

[0044] The composite rack 2 may have rack units A, B, C, which havedifferent designs at least partially in terms of the depth of the rack,the height of the rack and/or the container type supports. Inparticular, special storage means, especially flow racks, may bearranged in the rack units A, B, C.

[0045] Two-sided rack serving devices 4, which serve two rack halveseach in the corresponding rack aisle 14, are used in the composite rack2 comprising three double racks arranged one after another according tothe drawings. It is apparent that racks 2 may also be provided withinthe framework of the present invention in the form of parallelindividual racks located at spaced locations from one another andoptionally combined with double racks, in which case the individualracks can be served by rack serving devices located on one side, whichcan be displaced at the front of the rack. However, the racks 2 aredivided into independent rack units A, B, C in the vertical direction inall embodiment variants.

[0046] The first embodiment variant according to FIGS. 1 through 4 isoperated by means of rack serving devices 4 according to FIGS. 5 and 6as follows.

[0047] Product to be dispatched is dispatched manually in containers 3at two individual dispatch places, not shown, which are connected to thetransport connections F1 and F2 without crossing.

[0048] Empty or partially emptied containers 3 (or full containers forfilling the rack) enter the region of the linear conveyor track 8connected vertically to the elevator 6 a on the circulating transportconnection F1 and F2. The containers are transferred there onto thelinear conveyor track 8 by cross slides, not shown and undergo interimstorage. The elevator 6 a takes over a container located there andtransports same onto the level of a selected rack unit A, B or C, inwhich a free storage site is present according to the computer controlwith path optimization. Once the level of the selected rack unit isreached, the elevator 6 a takes over the container 3 of the linearconveyor track 8 located there, which leads to the stationary parkingspace 9 located on the same level. The container is then ready on theparking space 9 for removal by the rack serving device 4 of thecorresponding rack unit A, B or C on the front side of the rack 2. Theactuated rack serving device 4 moves to this parking space 9 and takesover the container 3 from there onto the aligned elevating platform 11.The rack serving device 4 then performs an accelerated and deceleratedmovement horizontally and at the same time vertically in the rack aisle14 to the empty storage site of the rack unit A, B or C and fills theempty storage site with the container 3.

[0049] A container 3 polled by the dispatch unit is retrieved from therack essentially in the opposite direction. However, after leaving therack serving device 4, the selected container 3 is brought on a separateconveyor track to the transport connection F1 and F2. The separateconveyor track is represented by the stationary parking space 9 and thelinear conveyor track 8, which are associated with the elevator 6 b. Adispatched container 3 transferred by this linear conveyor track 8 tothe transport connection F1 and F2 reaches the dispatch unit withoutcrossing.

[0050] Consequently, containers 3 are stored and retrieved on separatepaths up to the rack serving device 4 according to the first embodimentvariant.

[0051] The second embodiment variant according to FIGS. 7 through 10 isoperated by means of rack serving devices 4 according to FIGS. 5 and 6similarly to the operation of the first embodiment variant. However, acommon elevator 5 is used both for the storage and the retrieval ofcontainers 3, which has a correspondingly large platform and can pick upcontainers to be stored and retrieved at the same time. The elevator 5is integrated in each buffer zone P1, P3 or P3 in a closed circulating,horizontal conveyor track 7, on which containers 3 are fed and removed,as can be seen, on separate paths between the transport connection F1and F2 and the elevator 5.

[0052] While specific embodiments of the invention have been shown anddescribed in detail to illustrate the application of the principles ofthe invention, it will be understood that the invention may be embodiedotherwise without departing from such principles.

1. A method for operating a rack system with a rack and an associated rack serving device for the storage and retrieval of containers, trays or the like to or from the rack, the method comprising: serving a rack region of the rack, which rack region has a plurality of rack planes arranged one above the other with the rack serving device; providing the rack serving deice as, a dedicated, mechanically coupled, height and length-adjustable rack serving device; taking over for storage and releasing for retrieval and transporting containers, trays or the like by means of at least one elevator and/or by a horizontal transport connection that is on the same level in the region of a rack unit from or to a transport system or workplace located outside the rack system, to provide that the containers, trays or the like undergo interim storage in each said rack region embodied as an independent and closed rack unit in a buffer zone arranged on the same level.
 2. A method in accordance with claim 1, wherein the containers, trays or the like are transported via the transport connection without crossing to or from an individual workplace, or to or from an individual dispatch place of a dispatch unit.
 3. A method in accordance with claim 1 whereineach said rack unit is reached by means of a dedicated electronic control means for the storage and retrieval of said containers, trays or the like.
 4. A method in accordance with claim 1 wherein at least a plurality of adjacent rack units are reached by means of a common electronic control means for the storage and retrieval of said containers, trays or the like.
 5. A method in accordance with claim 1, wherein the containers, trays or the like are transported in one direction and are stored on an interim basis in the buffer zone on a closed conveyor track.
 6. A method in accordance with claim 1, wherein the containers, trays or the like are transported and stored on an interim basis in the buffer zone on a open and linear conveyor track.
 7. A method in accordance with claim 1 wherein the containers, trays or the like undergo interim storage in the buffer zone on said stationary parking spaces.
 8. A method in accordance with claim 1 wherein said containers, trays or the like are fed and removed by means of said separate elevators.
 9. A rack serving system for serving a rack divided into at least two rack regions arranged one above the other, the system comprising: a plurality of adjacent rack planes each arranged one above the other, wherein each said rack region is embodied as an independent and closed rack unit; a dedicated, mechanically coupled, height- and length-adjustable rack serving device for each rack unit; a transfer station for each rack unit, the transfer station being a rigid part of the rack; a buffer zone, said transfer station being arranged on the same level with said buffer zone for said containers, trays or the like, in which containers, trays or the like are taken over for storage or are released for retrieval; and an elevator, which is connected to the buffer zone and is a rigid part of the rack, and/or a transport connection, which is connected to each said buffer zone and is a rigid part of the rack and is horizontal in the rack region for feeding or removing said containers, trays or the like to or from a transport system or workplace located outside the rack system.
 10. A rack serving system in accordance with claim 9, wherein the transport connection, which is arranged on the same level in the region of the rack unit, is led without crossing directly to and from an individual workplace, especially directly to and from an individual dispatch place of a dispatch unit, as a closed circulating conveyor track, on which containers dispatched from the rack are transported to the workplace and conversely, said empty or partially emptied containers, trays or the like are transported from the workplace to the rack.
 11. A rack serving system in accordance with claim 9, wherein a dedicated electronic control means is provided for each said rack unit for the storage and retrieval of said containers, trays or the like.
 12. A rack serving system in accordance with claim 9 wherein a common electronic control means is provided for at least a plurality of preferably adjacent rack units for the storage and retrieval of said containers, trays or the like.
 13. A rack serving system in accordance with claim 9, wherein the buffer zone has a, preferably closed and horizontal conveyor track with a connection to a elevator, on which said conveyor track said containers 3, trays or the like are conveyed in one direction and stored on an interim basis and are transferred to the elevator or are taken over from the elevator.
 14. A rack serving system in accordance with claim 9, wherein the buffer zone has an open, linear, horizontal conveyor track, on which said containers, trays or the like are conveyed and undergo interim storage.
 15. A rack serving system in accordance with claim 9, wherein the buffer zone has stationary parking spaces at the rack for the interim storage of said containers, trays or the like.
 16. A rack serving system in accordance with claim 9, wherein said containers, trays or the like are fed and removed by means of said separate elevators.
 17. A rack serving system in accordance with claim 9 wherein each said rack unit is accessible by means of a ladder.
 18. A rack serving system in accordance with claim 9 wherein the rack has said rack units, which have different designs at least partially in terms of the depth of the rack, the height of the rack and/or the container type supports.
 19. A rack serving system in accordance with claim 9, wherein the rack has said rack units, in which special storage means including flow racks, are arranged.
 20. A rack serving system in accordance with claim 9, wherein the rack is composed of a number of parallel individual racks located at spaced locations from one another and/or double racks, wherein the individual racks are served from a front of the rack by said rack serving devices located on one side and the double racks are served in a rack aisle located between them by said two-sided rack serving devices.
 21. A rack serving system in accordance with claim 9 wherein the rack serving device has an elevating chassis and an elevating platform of a low overall height essentially at the same level, wherein the elevating chassis and the elevating platform are arranged on opposite sides of a longitudinally displaceable elevator mast.
 22. A rack serving system in accordance with claim 21, wherein the elevator mast extends over the height of a rack unit and is guided at least at the bottom in a longitudinal guide rail, which is an integral part of the rack. 